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EP/L505158/1 - Novel 3D coating of bioactive glass and metallic composites

Research Perspectives grant details from EPSRC portfolio

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Professor WM Rainforth EP/L505158/1 - Novel 3D coating of bioactive glass and metallic composites

Principal Investigator - Materials Science and Engineering, University of Sheffield

Other Investigators

Professor JW Haycock, Co InvestigatorProfessor JW Haycock

Professor I Todd, Co InvestigatorProfessor I Todd

Scheme

Technology Programme

Research Areas

Manufacturing Technologies Manufacturing Technologies

Start Date

09/2013

End Date

08/2015

Value

£145,478

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Grant Description

Summary and Description of the grant

The orthopaedic implant market is consistently projected to show strong growth, particularly in the joint reconstruction
sector. At a time where healthcare budgets are under severe pressure, there is a need for novel hip implants that deliver a
better quality of clinical outcome, but at the same or reduced cost. Implants are coated to aid implant bone-integration, and
the composition and structure of these coating is critical to the speed and strength of implant-bone integration and hence
the clinical outcome. The current coating is a combination of titanium (for strength) and bioactive glass (to facilitate bone
ingrowth), materials which have very different thermal properties and therefore must be laid down in two-stages if using a
conventional coating process. The ability to apply these materials by a novel 3D printing process, potentially in one-step,
will transform design and manufacture of orthopaedic implants. It will provide much greater design freedom to create new
functionally optimised material combinations and structures not achievable by a conventional process. This project
integrates the capabilities of SMEs operating end-to-end from design to product supply and the expertise of the University
of Sheffield in end-to-end simulation. Using a range of simulation methodologies developed by UoS in a series of
previously funded programmes (e.g. IMMPETUS EPSRC grants, EP/E063497 and EP/F023464), the Mercury Centre will
apply these to design and simulate the end-to-end manufacturing of the novel 3D coating of bioactive glass and metallic
composites. We will use phase field modelling to simulate the melting, fluid dynamics, solidification and phase
transformations during AM to optimise the process conditions for this application. We will use our unique combined finite
element/discrete element modelling to simulate the heat transfer, residual stresses and interaction between the metal and
bioglass. Multi-scale modelling will be used to link microstructure and properties throughout the manufacturing process.
This will extended to include the behaviour of the novel composite in vivo. It will deliver from design to supply a novel
additive manufacturing (AM) process to apply novel interpenetrating 3D glass and metallic composite coatings onto 3D
surfaces initially for orthopaedic (hip) implants. The coatings will enable design and manufacture of smaller (minimally
invasive) implants with 'large implant' performance having better mechanical stability and faster integration with bone thus
improving long-term clinical performance and a reduced revision rate. This delivers a significantly better clinical outcome
for patients and savings for the health service. The envisaged AM process has the potential to be faster and lower cost
than current two-stage deposition and to enable the manufacture (possibly in near-patient areas) of implants matched to
the patient using pre-operative bone scans. Transferability to other sectors will be demonstrated by the manufacture of a
solar diffuser material.

Structured Data / Microdata


Grant Event Details:
Name: Novel 3D coating of bioactive glass and metallic composites - EP/L505158/1
Start Date: 2013-09-01T00:00:00+00:00
End Date: 2015-08-31T00:00:00+00:00

Organization: University of Sheffield

Description: The orthopaedic implant market is consistently projected to show strong growth, particularly in the joint reconstruction sector. At a time where healthcare budgets are under severe pressure, there is a need for novel hip implants that deliver a better qu ...